Use a quarter round trim strip to form the corner, where you have a
radius on the outside, and a square corner inside, which you can trim
or fillet. For other than 90 degree corners, trim the strip on a
table saw. Use thin plywood and build up the edges to meet the trim
strip depth and accept screws holding it together.

Arrange to remove the plywood mold plug from the inside by covering
the outside with waxed paper. After you have built up sufficient
thickness of glass, drill out the screw heads and remove the screws to
remove the mold panels. Fill the screw holes.

I considered just glassing over the old canvas, for that slouch hatted
look.

Terry K

On Aug 23, 11:05 am, Terry K wrote:
Use a quarter round trim strip to form the corner, where you have a
radius on the outside, and a square corner inside, which you can trim
or fillet. For other than 90 degree corners, trim the strip on a
table saw. Use thin plywood and build up the edges to meet the trim
strip depth and accept screws holding it together.

Arrange to remove the plywood mold plug from the inside by covering
the outside with waxed paper. After you have built up sufficient
thickness of glass, drill out the screw heads and remove the screws to
remove the mold panels. Fill the screw holes.

I considered just glassing over the old canvas, for that slouch hatted
look.

Terry K

Thanks Terry, that is very helpful.

I think you are suggesting that I make rounded corners from molds, to
be added to the structure afterwards. So I would make the structure
using wood in the corners to provide strength, and then add the
rounded corners and finish them. that is my interpretation..

I might be able to use the existing cabin-house as a male mold to get
the same curve? Using wax paper and protecting the area with plastic,
I could perhaps use fiberglass and epoxy to form the corners for
adding to the dodger later. Let me know if you think this is a crazy/
unworkable idea.

Thanks for the ideas.

-Koos.